Carton flap folder

ABSTRACT

An apparatus and associated method for folding a flap on a work piece. The apparatus comprises a central frame, and a reference surface supported by the frame operatively receivingly engaging the work piece. A positioning and folding device comprises a circular pin extendable over the reference surface and longitudinally moveable to abuttingly engage and position the work piece. An actuator rotates the pin between a first position and a second position. A tamping member extends from the pin and defines an abutting surface abuttingly engaging the work piece in the first position of the pin. A folding member extends from the distal end of the tamping member, and is clearingly angled away from the work piece in the first position of the pin. The folding member foldingly engages the flap in the second position of the pin. The pin maintains the abutting engagement against the work piece at the first and second positions and therebetween.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 60/337,267.

FIELD OF THE INVENTION

[0002] This invention relates generally to the field of automated fabrication devices and more particularly without limitation to a device for folding a work piece.

BACKGROUND OF THE INVENTION

[0003] Tremendous gains in manufacturing productivity and quality have been realized by the application of modem automation techniques to production processes. Most of the earliest advancements involved automating fabrication processes, such as numerically controlled tooling machines. Typically, the work piece was manually installed into a fixture, or “fixtured,” the computer-controlled process performed, and then the work piece was manually removed from the fixture. Subsequent advancements improved the material handling aspects of the process, such as with the proliferation of robotics. Today, it's not unusual to see all aspects of the fabrication process from raw material to packaging performed by flexible manufacturing cells connected by material transfer devices.

[0004] Flexible manufacturing approaches are typically able to process different types of parts so that one cell can be used in the manufacture of different products. For example, a packaging cell might be able to receive different size containers for use in packaging different sizes or types of products. This flexibility furthermore aids the development of new and different products because the likelihood of consequential costly modifications and downtime to the manufacturing process are greatly diminished.

[0005] Automatic folding can be problematic when processing a plurality of different size work pieces. Accordingly, it is not unusual to see human assistance necessary in operations requiring folding operations on work pieces. The penalty associated with relying on manual intervention can be very significant.

[0006] It has been determined that folding operations on a plurality of different work piece such as this can be automatically done reliably by providing a positioning and folding device that simultaneously position and fold the work piece. It is to these improvements and others as exemplified by the description and appended claims that embodiments of the present invention are directed.

SUMMARY OF THE INVENTION

[0007] The embodiments of the present invention contemplate an apparatus and an associated method for folding a flap on a work piece. The apparatus comprises a central frame and a reference surface supported by the frame operatively receivingly engaging the work piece. The apparatus further comprises means for folding the flap by employing a positioning and folding device that simultaneously positions the work piece and folds the flap.

[0008] In embodiments of the present invention the apparatus comprises a positioning and folding device comprising a circular pin extendable over the reference surface and longitudinally moveable to abuttingly engage and position the work piece. An actuator rotates the pin between a first position and a second position. A tamping member extends from the pin and defines an abutting surface abuttingly engaging the work piece in the first position of the pin. A folding member extends from the distal end of the tamping member, and is clearingly angled away from the work piece in the first position of the pin. The folding member foldingly engages the flap in the second position of the pin. The pin maintains the abutting engagement against the work piece at the first and second positions and therebetween.

[0009] The positioning and folding device is preferably moveable transversely to the reference surface accommodating work pieces of various heights. A sensor can detect the height of the work piece, and a controller can be responsive to the sensor for automatically moving the positioning and folding device in accordance with the height of the work piece.

[0010] In some embodiments the work piece with the flap in the unfolded state defines an open ended carton, and the apparatus further comprises a plunger that is extendable into the open end and is adapted for moving any portion of an object that is partially extending outside the carton into the carton.

[0011] One aspect of the embodiments of the present invention contemplates a method for automatically folding a work piece having a foldable flap. The method comprises positioning the work piece in a reference position by abuttingly engaging the work piece with a round positioning member. The method further comprises providing a clamping member depending from the positioning member and defining a clamping surface clamping the work piece in the clamped position of the clamping member. The method further comprises rotating the positioning member while maintaining the abutting engagement therewith the work piece, thereby pressingly engaging a distal end of the clamping member against the flap to fold the flap at a desired angle. The method can further comprise determining the height of the work piece and responsively positioning the positioning member, and pushing any portion of an object that is partially extending outside the carton into the carton before the rotating step.

[0012] These and various other features as well as advantages which characterize the present invention will be apparent upon reading of the following detailed description and review of the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is an isometric view of a flap folding apparatus constructed in accordance with embodiments of the present invention.

[0014]FIG. 2 is a side elevational view of the apparatus of FIG. 1.

[0015]FIG. 3 is a rear elevational view of the apparatus of FIG. 1.

[0016]FIG. 4 is a diagrammatic illustration of the folding operation of the apparatus of FIG. 1.

[0017]FIG. 5 is a block diagram illustrating the sensor controlling of the vertical position of the positioning and folding device.

DETAILED DESCRIPTION

[0018] Referring to the drawings in general, and more particularly to FIG. 1, shown therein is an isometric view of a folding apparatus 10 for folding a flap on a work piece (not shown in FIG. 1). For purposes of illustration a work piece forming a carton with a closeable side will be used in the discussion hereinbelow. Such a carton is typically used in packaging a product for safe transit and storage.

[0019] The folding apparatus 10 comprises a central frame 12 comprising a plurality of structural frame components joined together to form a skeletal support system. A reference surface 14 is supported by the central frame 12 for operatively receivingly engaging the work piece. In FIG. 1, for example, the reference surface 14 comprises a roller conveyor adapted for singulating a work piece and moving it into a working zone of the folding apparatus 10.

[0020] The folding apparatus 10 comprises a positioning and folding device 16 for positively locating the work piece on the reference surface 14 and then performing a folding operation on the work piece. The positioning and folding device 16 is adapted to automatically receivingly engage and fold a number of different size work pieces. Lateral positioning is performed by a pair of opposing retractable pusher plates 18 positioned by an actuator such as a rodless fluid cylinder 20. FIG. 1 illustrates the pusher plates 18 in the retracted position whereat any particular size carton within a preselected family of cartons can enter the work zone on the reference surface 14. FIG. 2 illustrates a work piece 22 laterally centered on the reference surface 14 by extensions of the opposing pusher plates 18 shown in dotted lines.

[0021] Returning to FIG. 1, for longitudinal positioning the positioning and folding device 16 further comprises a pair of retractable circular pins 24 positioned by an actuator such as a rodless fluid cylinder 26. Although the embodiments illustrated in the drawings and description hereinbelow contemplates a pair of opposing pins 24, alternative embodiments can employ a single pin 24 to push the work piece 22 to the desired position, wherein frictional engagement between the work piece 22 and the reference surface 14 resists the pushing force.

[0022]FIG. 1 illustrates the pins 24 in the retracted position whereat any particular size carton within a preselected family of cartons can enter the work zone on the reference surface 14. FIG. 3 illustrates the actuators 26 are supported by a linear actuator 28 for moving the pins (not shown in FIG. 3) toward each other into opposing engagement against the work piece 22. FIG. 4 diagrammatically illustrates this opposing pressing engagement of the pins 24 to longitudinally position the work piece 22 upon the reference surface 14.

[0023] The positioning and folding device 16 further comprises a rotary actuator 30 (FIG. 1) for rotating the pin 24 between a first position and a second position, as best illustrated in FIG. 4. A tamping member 32 extends from the pin 24 defining an abutting surface 34 abuttingly engaging the work piece 22 in the first position of the pin 24. A folding member 36 extends from the distal end of the tamping member 32 clearingly angled away from the work piece 22 in the first position of the pin 24. In the second position of the pin 24, the folding member 36 (shown in broken lines) foldingly engages a flap 38 to fold the flap 38 and close the work piece 22. Any of a number type of sealing means can be employed to adhere the flaps 38 in the folded state. It will be noted that the pin 24 maintains the abutting engagement against the work piece 22 at the first and second positions and all positions therebetween, thereby maintaining the longitudinal positioning of the work piece 22 during the folding operation.

[0024] The positioning and folding device described hereinabove effectively positions any of a plurality of different size work pieces 22 in the lateral and longitudinal directions of the reference surface 14. Additionally, provision can be made to accommodate work pieces 22 of different heights as well. For example, FIG. 2 illustrates the linear actuator 28, which supports the rotary actuators 30, being supported by an actuator 40 such as a rodless fluid cylinder. Accordingly, the linear actuator 28 portion of the positioning and folding device 16 is moveable transversely to the reference surface 14.

[0025] Preferably the folding apparatus 10 is equipped to automatically detect the height of an incoming work piece 22 and control the actuator 40 to appropriately position the pins 24 for folding the flaps 38. In some embodiments, for example, an optical sensor 42 detects the height of the work piece 22 on the reference surface 14. FIG. 5 illustrates the manner in which the sensor 42 sends a signal 44 to a controller 46 which, in turn, sends a signal 48 controlling the position of the actuator 40. A position feedback signal 50 can be employed in a positive feedback control loop. In alternative embodiments the sensor 42 can comprise a scanner adapted to read a bar code label 52 (FIG. 4) on the work piece 22 that is indicative of the work piece height.

[0026]FIG. 2 illustrates the folding apparatus 10 can comprise a plunger 54 that is extendable, such as by a rodless fluid cylinder 56, so as to press downward into the work piece 22 before it is closed by the folding operation. This permits moving any portion of an object that has become partially extended outside the work piece into the work piece so as to not obstruct the folding operation. Preferably, the plunger 54 has an angled contacting surface so that dunnage materials, such as an inner liner, is packed into the work piece in a repeatable manner.

[0027] As described, the folding apparatus 10 generally comprises a central frame supporting a reference surface 14 receivingly engaging the work piece 22, and means for folding the flap 38 by employing a positioning and folding device that simultaneously positions the work piece 22 and folds the flap 38. The embodiments of the present invention contemplate the means for folding to encompass not only that which is explicitly illustrated and described but equivalent alternative embodiments as well.

[0028] For example, and without limitation, in embodiments of the present invention and equivalent embodiments the means for folding is generally characterized by a positioning and folding device comprising a circular pin extendable over the reference surface and longitudinally moveable to abuttingly engage and position the work piece; an actuator rotating the pin between a first position and a second position; a tamping member extending from the pin and defining an abutting surface abuttingly engaging the work piece in the first position of the pin; a folding member extending from the distal end of the tamping member clearingly angled away from the work piece 22 in the first position of the pin 24, and foldingly engaging the flap 38 in the second position of the pin 24, wherein the pin 24 maintains the abutting engagement against the work piece 22 at the first and second positions and positions therebetween.

[0029] Embodiments of the present invention furthermore contemplate means for folding that are characteristically moveable transversely to the reference surface accommodating work pieces of various heights. The means for folding can comprise the sensor 42 and a controller 46 responsive to the sensor 42 for controlling the transverse movement.

[0030] Another aspect of the embodiments of the present invention contemplates a method for automatically folding a work piece having a foldable flap. The method comprises positioning the work piece in a reference position by abuttingly engaging the work piece with a round positioning member; providing a clamping member depending from the positioning member and defining a clamping surface clamping the work piece in the clamped position of the clamping member; rotating the positioning member while maintaining the abutting engagement therewith the work piece, thereby pressingly engaging a distal end of the clamping member against the flap to fold the flap at a desired angle. The method can comprise determining the height of the work piece 22 and responsively positioning the positioning member. The method can further comprise pushing any portion of an object that is partially extending outside the work piece into the work piece before the rotating step.

[0031] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the manner in which the work piece is moved into or out of the work zone may vary while maintaining substantially the same functionality without departing from the scope and spirit of the present invention. In addition, although the preferred embodiment described herein is directed to use with a work piece comprising a carton, it will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other work pieces as well such as fabrication processes on foldable materials without departing from the scope and spirit of the present invention. 

What is claimed is:
 1. An apparatus for folding a flap on a work piece, comprising: a central frame; a reference surface supported by the frame operatively receivingly engaging the work piece; a positioning and folding device comprising: a circular pin extendable over the reference surface and longitudinally moveable to abuttingly engage and position the work piece; an actuator rotating the pin between a first position and a second position; a tamping member extending from the pin and defining an abutting surface abuttingly engaging the work piece in the first position of the pin; a folding member extending from the distal end of the tamping member clearingly angled away from the work piece in the first position of the pin, and foldingly engaging the flap in the second position of the pin, the pin maintaining the abutting engagement against the work piece at the first and second positions and therebetween.
 2. The apparatus of claim 1 wherein the positioning and folding device is moveable transversely to the reference surface adaptively accommodating work pieces of various heights.
 3. The apparatus of claim 2 further comprising a sensor detecting the height of the work piece.
 4. The apparatus of claim 3 wherein the sensor comprises a scanner adapted to read a bar code placed on the work piece indicative of the work piece height.
 5. The apparatus of claim 3 further comprising a controller responsive to the sensor for automatically moving the positioning and folding device in accordance with the height of the work piece.
 6. The apparatus of claim 1 comprising a pair of positioning and folding devices moveable toward each other and opposingly engageable against the work piece.
 7. The apparatus of claim 1 comprising a second positioning device positioning the work piece along an axis different than the longitudinal axis associated with the pin.
 8. The apparatus of claim 1 wherein the work piece with the flap in the unfolded state defines an open ended carton, the apparatus further comprising a plunger extendable into the open end and adapted for moving any portion of an object that is partially extending outside the carton into the carton.
 9. A folding apparatus for work pieces having a foldable flap, comprising: a central frame supporting a reference surface receivingly engaging the work piece; and means for folding the flap by employing a positioning and folding device that simultaneously positions the work piece and folds the flap. 10 The folding apparatus of claim 9 wherein the means for folding is characterized by a positioning and folding device comprising: a circular pin extendable over the reference surface and longitudinally moveable to abuttingly engage and position the work piece; an actuator rotating the pin between a first position and a second position; a tamping member extending from the pin and defining an abutting surface abuttingly engaging the work piece in the first position of the pin; a folding member extending from the distal end of the tamping member clearingly angled away from the work piece in the first position of the pin, and foldingly engaging the flap in the second position of the pin, the pin maintaining the abutting engagement against the work piece at the first and second positions and therebetween.
 11. The folding apparatus of claim 9 wherein the means for folding is characteristically moveable transversely to the reference surface accommodating work pieces of various heights.
 12. The folding apparatus of claim 11 wherein the means for folding further comprising a sensor detecting the height of the work piece.
 13. The folding apparatus of claim 12 wherein the means for folding comprises a sensor characterized by a scanner adapted to read a bar code placed on the work piece indicative of the work piece height.
 14. The folding apparatus of claim 12 wherein the means for folding is characterized by a controller responsive to the sensor for automatically moving the positioning and folding device in accordance with the height of the work piece.
 15. The folding apparatus of claim 9 wherein the means for folding is characterized by a pair of positioning and folding devices moveable toward each other and opposingly engageable against the work piece.
 16. A method for automatically folding a work piece having a foldable flap, comprising: positioning the work piece in a reference position by abuttingly engaging the work piece with a round positioning member; providing a clamping member depending from the positioning member and defining a clamping surface clamping the work piece in the clamped position of the clamping member; rotating the positioning member while maintaining the abutting engagement therewith the work piece, thereby pressingly engaging-a distal end of the clamping member against the flap to fold the flap at a desired angle.
 17. The method of claim 16 further comprising determining the height of the work piece and responsively positioning the positioning member.
 18. The method of claim 16 further comprising pushing any portion of an object that is partially extending outside the carton into the carton before the rotating step. 